You're facing production delays due to maintenance issues. How can you ensure your schedule stays on track?

A good plant has operations and maintenance working together to identify issues before they shut down a line and for quicker repair to minimize downtime. This includes the identification of failure points and proper planning of maintenance tasks to minimize failures. Operators noting changes in equipment performance during daily operation, preventive inspections and a qualified maintenance team will improve performance.

This is not a simple answer. So many factors will determine the success of the operation. So, let's start with production. Any ERPII system in manufacturing should have the capability to put equipment "On Vacation" so maintenance can be scheduled on that equipment. That's a start. On the engineering side, FMEA/FMECA/RCM should be conducted to identify failures and the appropriate maintenance strategy to mitigate or eliminate. On the Maintenance side of the equation, well developed PM's, moving towards condition-based strategies, skills & competency, scheduling that meld with operations schedule, a robust supply chain & MRO Storeroom, and finally overarching management support of the processes All working in perfect harmony!

Great examples - consistent communication between Operations and Maintenance teams, at all levels (tech/operators, leaders, etc). This includes floor walks, both random and planned, as well as scheduled touch points to ensure leadership is aligned on strategy and tactical movements. The criticality of proactive maintenance can't be understated, as it's entire purpose is to avoid maintenance issues derailing schedule attainment. Foundations to prop all of this up - sound and accurate data collection and analysis of the equipment and processes...this will ensure all parties have the facts and clarity to understand the necessary actions to avoid unplanned downtime. Finally the need for well-trained, accountable personnel.

We are still moving from a paper-based society to electronic communication in the industrial world. Some maintenance supervisors have stacks of work orders on their desks while others communicate using tablets. Communication methods include daily meetings, radio communications for closest technicians to using an MS Teams program to post to every tech in the field that carries a tablet. Use the method that works best for your situation.

At one company, I analyzed the MRO inventory and compared it to usage data that was available. I noticed some major gaps. After looking at the lead times for some spare parts (more than 6 months), I ordered twice what usage said I would need. Two weeks after they were on site, I used 1/2 of the order and then my levels were at the correct point to support the facility. An emergency order for those parts would have kept the line down for 30 days.

Para una Gestión de Inventarios efectiva, primero hay que tener definido el árbol de equipos, su criticidad y cuáles son los repuestos críticos de esos equipos críticos para poder definir el stock óptimo y el punto de pedido correspondiente, lo que debe ser administrado con el software correspondiente

In some process industries annual, or longer frequency shutdowns are mandated due to risk management of assets required total site outage. Typically operating personnel are furloughed for this duration. At one facility we kept the operators working, teamed with maintenance workers providing welcomed assistance and expanding the resources available to perform more work. The intangible benefit was knowledge gained, informally, by both, of each others problems with asset performance issues. A tangible benefit of this collaboration occurred when Operator Driven Reliability (ODR) was later introduced and was more easily implemented.

Many industries have moved to a multi-skilled maintenance workforce. Training is conducted in mechanical and electrical tasks with some specialization for more complex tasks. This provides flexibility when equipment needs maintenance.